''I've mostly moved to foil and PBC. Argon is expensive, and it doesn't prevent oxidation during the quench. I love having bright clean D2 after HT, because my little surface grinder doesn't like hard D2. What did I do before foil...''
Is this why you quench in the foil and remove it first?
Yes, and the foil is not slowing down a plate quench very much. Plate quenching works great through foil, though an air quench wouldn't. So, for the cleanest parts, I quench with foil on the parts. If I had irregular parts that don't lend themselves to plate quench, I'd heat in argon and air quench and tumble or grind the little bit of scale off. But sometimes my little grinder doesn't do well on hard D2, it is a dry grinder.
Foil is cheep and 50 feet is gonna last you a long time. I use the high temp stuff (309), because D2 is a bit above the range of the regular stuff, and I'm not gonna risk a $1,000 machined part. But plenty of folks use the regular stuff to 2000F and beyond.
I make an envelope. First I cut off a piece of foil. I fold in in half. I fold over a seam on an edge, about an inch. Then I fold that seam again in half. I use a roller to keep the seams tight. Then I do the other side. Then I put the part in. Then I cut myself on the foil and find gloves. Then I double seam the end. Then I shake the envelope around until the part is centered and kinda squeeze around it to hold it in place, wouldn't want a thick seam to hold the plate off the part in a spot during quench.
You're supposed to quench with thick aluminum plates, but I use heavy thick steel plates. It is still way faster cooling than air quench, and as Kevin has pointed out, there is no point quenching faster than the TTT nose for your steel indicates. Though I'm not sure that's the whole story.